Bonded structures formed form multicomponent fibers having elastomeric components for use as ink reservoirs

ABSTRACT

A bonded fiber ink reservoir, an ink jet printer cartridge containing a bonded fiber reservoir, and a ink jet printer using an ink jet cartridge containing a bonded fiber reservoir are disclosed. The bonded fiber reservoir may comprise a three dimensional bonded fiber structure, wherein the three dimensional bonded fiber structure is comprised of a plurality of fibers bonded to each other at spaced apart points of contact, at least a portion of the fibers being multicomponent fibers having at least one elastomeric fiber component.

This application claims priority to U.S. Provisional Application Ser.No. 60/664,032, titled “Elastomeric Bicomponent Fibers and BondedStructures Formed Therefrom,” filed on Mar. 22, 2005, and U.S.Provisional Application Ser. No. 60/737,342, titled “Ink ReservoirsFormed From Elastomeric Bicomponent Fibers,” filed on Nov. 16, 2005,both of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The invention relates generally to the field of multicomponent fibersand bonded fiber structures. More particularly, the invention isdirected to three dimensional self-sustaining bonded fiber structurescomprised of multicomponent elastomeric fibers. More particularly still,the invention relates to ink reservoirs formed of such three dimensionalself-sustaining bonded fiber structures comprised of such elastomericfibers.

Multicomponent fibers are typically manufactured by melt spinningtechniques (including conventional melt spinning, melt blowing, spunbond, and other melt spun methods). Multicomponent fibers may bemanufactured in a side-by-side structure, a centric sheath-corestructure, or an acentric (e.g. self-crimping) sheath-core structure.Such fibers can be used in continuous filament or staple form and/orcollected into webs or tows. They may be produced alone or as part of amixed fiber system. Multicomponent fibers can be used for a variety ofpurposes, including but not limited to woven and non-woven fabrics orstructures and bonded or non-bonded structures.

As described in U.S. Pat. Nos. 5,607,766, 5,620,641, 5,633,082,6,103,181, 6,330,883, 6,814,911, and 6,840,692, each of which isincorporated herein by reference in its entirety, there are many formsof and uses for bonded fiber structures, as well as many methods ofmanufacture. In general, such bonded fiber structures are formed fromtows or webs of thermoplastic fibrous material, where the bonded fiberstructure comprises an interconnecting network of highly dispersedfibers bonded to each other at points of contact. These webs are formedinto substantially self-sustaining, three-dimensional porous componentsand structures, which may be produced in a variety of sizes and shapes.

Porous, bonded structures formed from multicomponent fibers havedemonstrated distinct advantages for fluid storage and fluidmanipulation applications, because such bonded fiber structures havebeen shown to take up liquids of various formulations and controllablyrelease them. A typical use for these structures may include use as nibsfor writing instruments, ink reservoirs for writing instruments and/orink jet printer cartridges, wicks for a wide variety of devices andapplications, depth filters, and other applications where thecharacteristics of such structures are advantageous. Many of theadvantageous characteristics of bonded fiber structures stem from thematerials used in the fibers from which these structures are formed.

The above-referenced patents describe a wide variety of polymermaterials that may be used to form fibers for use in three dimensionalbonded structures. These structures, however, are often unsuitable forcertain applications where resiliency or penetrability is required.Additionally, the ability of these structures to take up liquids ofvarious formulations, hold these liquids during various environmentalconditions, and controllably release these liquids is often less thandesirable. Accordingly, there is a need for resilient bonded fiberstructures that exhibit desirable fluid storage and manipulationcharacteristics.

These characteristics are desirable for ink jet printers. Ink jetprinters often use an ink jet print-head mounted within a carriage. Asthe carriage moves across a media (i.e., paper), the ink jet print-headwithdraws ink from an ink reservoir, and deposits the ink appropriatelyon the media (i.e., in the shape of letters). The ink reservoir istypically contained in an ink jet printer cartridge. The ink jet printercartridge generally encases the ink reservoir. The ink jet printercartridge may be disposed on the carriage adjacent to the print-head, orit may be disposed elsewhere in the ink jet printer and may deliver inkto the print-head.

Various materials may be used as the ink reservoir. Typical materialsinclude open cell foam, and fibrous structures, such as felt. Inselecting a material for the ink reservoir, several characteristics areconsidered. These characteristics primarily surround the material'sfluid manipulation qualities. For example, capillarity strength, surfaceenergy, porosity, leak resistance, resistance to imparting debris orextractibles into the ink, ease of assembly, and ink extraction may beexamined.

However, these qualities must also be considered in light of varioustesting conditions. For example, ink jet printer cartridges must notleak during atmospheric pressure changes that may occur during shipping.Additionally, ink jet printer cartridges must not leak during certainimpacts, such as if the ink jet printer cartridge is accidentallydropped. Finally, ink jet printer cartridges must deliver as much ink aspossible to the print-head, rather than leaving unusable ink stranded inthe cartridge.

Accordingly, it is desirable to find a material for use in an inkreservoir that retains ink during various environmental conditions,allows the ink to be easily extracted from the ink reservoir, and allowsfor the extraction of a high percentage of the ink.

SUMMARY OF THE INVENTION

Aspects of the invention include a bonded fiber ink reservoir, an inkjet printer cartridge containing a bonded fiber reservoir, and an inkjet printer using an ink jet cartridge containing a bonded fiberreservoir. The bonded fiber reservoir may comprise a three dimensionalbonded fiber structure, wherein the three dimensional bonded fiberstructure is comprised of a plurality of fibers bonded to each other atspaced apart points of contact, at least a portion of the fibers beingmulticomponent fibers having at least one elastomeric fiber component.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory only,and are not restrictive of the invention as claimed. The accompanyingdrawings constitute a part of the specification, illustrate certainembodiments of the invention and, together with the detaileddescription, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to assist in the understanding of the invention, reference willnow be made to the appended drawings, in which like reference charactersrefer to like elements. The drawings are exemplary only, and should notbe construed as limiting the invention.

FIG. 1 is an isometric view of an ink jet cartridge, in accordance withsome embodiments of the invention.

FIG. 2 is a cross-sectional view of an assembled ink jet cartridge, inaccordance with some embodiments of the invention.

FIG. 3 is a cross-sectional view of a concentric sheath-coremulticomponent fiber, used to form three dimensional self-sustainingbonded fiber structures, in accordance with some embodiments of theinvention.

FIG. 4 is a cross-sectional view of an acentric sheath-coremulticomponent fiber, used to form three dimensional self-sustainingbonded fiber structures, in accordance with some embodiments of theinvention.

FIG. 5 is a cross-sectional view of a side-by-side multicomponent fiber,used to form three dimensional self-sustaining bonded fiber structures,in accordance with some embodiments of the invention.

FIG. 6 is a cross-sectional view of a multicomponent fiber, used to formthree dimensional self-sustaining bonded fiber structures, in accordancewith some embodiments of the invention.

FIG. 7 is a cross-sectional view of a multicomponent fiber, used to formthree dimensional self-sustaining bonded fiber structures, in accordancewith some embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention provide multicomponent fibershaving one or more elastomeric components that can be used to formresilient bonded fiber structures. As used herein, the term“multicomponent fiber” refers to a fiber having two or more distinctcomponents integrally formed from polymer materials having differentcharacteristics and/or different chemical nature. Bicomponent fibers area particular type of multicomponent fiber. As used herein, the term“bicomponent fiber” refers to a fiber having two distinct componentsintegrally formed from polymer materials having differentcharacteristics and/or different chemical nature. While other forms ofbicomponent fiber are possible, the most common types are formed with“side-by-side” or “sheath-core” relationships between the two polymercomponents. For example, bicomponent fibers comprising a core of onepolymer and a coating or sheath of a different polymer are particularlydesirable for many applications since the core material may berelatively inexpensive, providing the fiber with bulk and strength,while a relatively thin outer component of a more expensive but uniquesheath material may provide the fiber with unique properties,particularly with respect to bonding.

As used herein, the term “elastomeric component multicomponent fiber” or“ECM fiber” means a multicomponent fiber having at least one componentcomprising an elastomeric material. The term “elastomeric componentbicomponent fiber” means a bicomponent fiber having at least onecomponent comprising an elastomeric material. As used herein the term“elastomeric material” refers to a macromolecular material that returnsrapidly to its initial dimensions and shape after substantialdeformation and release of stress.

As used herein, the term “fluid” means a substance whose molecules movefreely past one another, including but not limited to a liquid or gas.The term “fluid” as used herein may also be multi-phase, and may includeparticulate matter suspended in a liquid or gas.

Reference will now be made in detail to embodiments of the invention,examples of which are illustrated in the accompanying drawings.

A particular application of three dimensional self-sustaining bondedfiber structures comprised of ECM fibers may be as an ink jet reservoir.Ink jet reservoirs made with ECM fibers have demonstrated severalbeneficial properties. For example, an ink jet cartridge using areservoir according to embodiments of the invention has been shown to beresistant to leakage and has unexpectedly demonstrated a high degree ofink-release from the cartridge. Test data have indicated that reservoirsformed from ECM fibers may be used with a wide variety of inkformulations. Further, the specific chemistry of the ECM fibers used,including any finishes, may be tailored to provide a particular surfaceenergy corresponding to the specific ink formulation with which theywill be used.

Ink reservoirs comprised of bonded ECM fibers may be resilient, orresistant to taking a compressive set, and may therefore provide amaterial which has a high degree of conformance to the interiorstructure of an ink jet reservoir cartridge. This increased conformancemay allow the reservoir to maintain contact with other ink conduitelements inside the cartridge. Maintaining contact to other suchelements under severe environmental conditions (e.g., thermal shock,physical shock or vibration, repeated removal and loading of thecartridge from the printer, etc.) may reduce the likelihood of failureof the cartridge.

Ink reservoirs comprised of bonded ECM fibers, in accordance with someembodiments of the invention may also exhibit properties that assist ineasier refilling. For example, the bonded fiber structure reservoir maybe penetrated with a large filling needle, and may reseal when theneedle is withdrawn. This may facilitate a more rapid filling that isconventionally achieved with standard, non-resilient fiber-basedreservoirs.

With reference to FIGS. 1 and 2, an ink jet printer cartridge 10 inaccordance with some embodiments of the invention will now be described.The ink jet printer cartridge 10, may be generally comprised of ahousing 100 and a reservoir 200.

Ink jet housing 100 and associated reservoirs may be generallyrectangular in shape, typically with 90 degree angles on all sides. Thedimensions of the cartridge can typically range from less than 5millimeters to 100 millimeters. A series of design considerations areoften employed, which may include designing a cartridge which can hold 6or more reservoirs and which will fit into typical ink jet printerdesigns. Non-rectangular shapes may also be employed, in which case, thereservoir(s) may be shaped accordingly.

The housing 100 may comprise an air vent 110, a fluid outlet 120, andstand-offs or baffles 130. The air vent 110 may generally be disposed onthe top surface of the housing 100, and may allow air to vent into thehousing 100, thereby allowing the even flow of ink out of the housing100. A void 111 may exist near the air vent 110, which may be used tocontain ink that may flow out of the reservoir 200 due to environmentalconditions. Additionally, the air vent 110 may be used, in certain typesof ink jet printer cartridges, to fill the ink jet printer cartridgewith ink during assembly.

The fluid outlet 120 may be disposed on the bottom of the housing 100.The fluid outlet may contact a printer head or other device which maydraw ink from the housing 100. The outlet may contain a wick, which maydraw the ink from the reservoir 200 via increased capillary strength.The stand-offs or baffles 130 may be shoulders or other detents integralto the housing, which may hold the reservoir 200 in a particularlocation.

The reservoir 200 may be comprised of a porous, three dimensional,self-sustaining bonded fiber structure formed from ECM fibers 210. Thebonded fiber structure reservoir 200 may have a certain capillarypressure that keeps ink inside the reservoir until drawn from thereservoir by either a print head pump or a higher capillary pressurewick. Additionally, the ink reservoir 200 may be designed to have enoughcapillary force to inhibit leakage as a result of mechanical shock orchanges in atmospheric pressure.

The bonded fiber ink reservoir 200 may be cut to dimensions suitable forthe housing 100. These dimensions may be slightly oversized, in order toensure a press-fit of the reservoir 200 in the housing 100. The networkof ECM fibers 210 that comprise the reservoir 200 retains and storesvarious formulations of ink through the ECM fiber's capillaritycharacteristics.

The methods of manufacture of ECM fibers and of three dimensionalself-sustaining bonded fiber structures formed from ECM fibers arethoroughly discussed in Applicant's copending application, assigned Ser.No. ______ , filed on Mar. 14, 2006 under Attorney Docket Number61633.001139, which is incorporated herein by reference in its entirety.

ECM fibers that may be used in some embodiments of the invention include(i) sheath-core multicomponent fibers where the sheath is comprised ofan elastomeric material and the core is comprised of a non-elasticmaterial; (ii) sheath-core multicomponent fiber where the sheath and thecore are both comprised of elastomeric materials with the core materialdifferent physical and/or thermal characteristics from the sheathmaterial; (iii) melt blown side-by-side bicomponent fibers, where onecomponent is comprised of an elastomeric material; and (iv) melt blownside-by-side bicomponent fibers, where both components are comprised ofelastomeric materials, and one component has different physical and/orthermal characteristics from the other.

With reference to FIGS. 3-7, various examples of ECM fiber embodimentsaccording to the invention will now be discussed in more detail.

FIG. 3 illustrates an exemplary ECM fiber of the invention. In thisembodiment, the fiber is formed as a sheath-core bicomponent fiber 300having a core component 310 surrounded by a sheath component 320,wherein the sheath component comprises a thermoplastic elastomer. Theuse of an elastomer as the sheath component 320 is particularlyadvantageous in that elastomeric materials generally bond easily to oneanother and to other fiber materials. When bonded, the core component310 of the sheath-core bicomponent ECM fiber 300 may provide strengthand stability to the fiber, while the elastomeric sheath component 320may allow the sheath-core bicomponent ECM fiber 300 to stretch relativeto other fibers to which it is bonded. This stretchable bond may providea resiliency to the bonded structure that is not attainable usingconventional sheath-core fibers.

The sheath-to-core ratio of ECM fibers of the invention may be tailoreddepending on the particular materials, the application of the fibers,and the method of manufacture. Typical sheath-to-core volume ratios maybe in a range from 10:90 to 90:10. In particular embodiments, thesheath-to-core volume ratio range from 25:75 to 40:60.

With continued reference to FIG. 3, the sheath-core bicomponent ECMfiber 300 is a concentric sheath-core fiber; that is, the sheath andcore have substantially concentric circular cross-sections. Other ECMfibers according to the invention may be formed as acentric sheath corefibers as exemplified by the acentric sheath-core ECM fiber 400 shown inFIG. 4. The acentric sheath-core ECM fiber 400 has a sheath component420 that comprises an elastomeric material and a core component 410. Inthis fiber, the sheath and core components may be substantially circularin cross-section, but with offset centers. This acentric geometry may beused to produce a self-crimping fiber, which may facilitate theproduction of a loftier, bulkier, and more elastic web.

Melt-blown ECM fibers according to the invention may also be formed in aside-by-side configuration, as exemplified by the side-by-side ECM fiber500 shown in FIG. 5. Like the sheath-core bicomponent ECM fiber 300, theside-by-side ECM fiber 500 has a first component 510 that comprises anelastomer and a second component 530. The side-by-side configurationassures that at least a portion of the surface of an elastomericcomponent 510 is exposed for bonding with other fibers.

ECM fibers of the invention are not limited to bicomponent fibers. Forexample, FIG. 6 illustrates a multicomponent ECM fiber 600 according tothe invention that has three components 610, 620, 630, any one or moreof which may comprise an elastomeric material.

ECM sheath-core fibers may also be produced with more than twocomponents. With reference to FIG. 7, a multicomponent sheath-core ECMfiber 700 may be comprised of a sheath component 730 that comprises anelastomeric material, an intermediate component 720, and a corecomponent 710. Similar fibers may be produced with acentric geometries.

The core components 310, 410, 710 of sheath-core ECM fibers 300, 400,700, the second component 510 of the side-by-side ECM fiber 500, and thesecond and third components 620, 630 of the side-by-side ECM fiber 600may be non-elastomeric or may comprise elastomeric materials havingdifferent material and/or thermal characteristics from the elastomericmaterials of the first fiber components 320, 420, 530, 620, 630 and 730.In some embodiments, core components 310, 410, 710 and side-by-sidecomponents 530, 620, 630 may comprise a crystalline or semi-crystallinepolymer. Such polymers may include, but are not limited to:polypropylene, polybutylene terephthalate, polyethylene terephthalate,high density polyethylene and polyamides such as nylon 6 and nylon 66.

The various elastomeric components of the ECM fibers of the inventionmay comprise any suitable elastomeric material. Suitable thermoplasticelastomers may include, but are not limited to: polyurethanes, polyestercopolymers, styrene copolymers, olefin copolymers, or any combination ofthese materials. More particularly, thermoplastic polyurethanes,thermoplastic ureas, elastomeric or plastomeric polypropylenes,styrene-butadiene copolymers, polyisoprene, polyisobutylene,polychloroprene, butadiene-acrylonitrile, elastomeric block olefiniccopolymers (such as styrene-isoprene-styrene), elastomeric blockco-polyether polyamides, elastomeric block copolyesters, and elastomericsilicones may be used.

Of these elastomeric materials, thermoplastic polyurethanes have beenshown to be particularly suitable for producing ECM fibers for use inbonded fiber structures. As used herein, the term “thermoplasticpolyurethane” or “TPU” encompasses a linear segmented block polymercomposed of soft and hard segments, wherein the hard segments are eitheraromatic or aliphatic and the soft segments are either linear polyethersor polyesters. The defining chemicals of TPUs are diisocyanates, whichreact with short chain diols to form a linear hard polymer block.Aromatic hard segment blocks are usually based in aromaticdiisocyanates, most commonly MDI (4,4′-Diphenylmethane diisocyanate).Aliphatic hard segment blocks are usually based in aliphaticdiisocyanates, most commonly hydrogenated MDI (H12MDI). Linear polyethersoft segment blocks commonly used include poly(butylene oxide) diols,poly(ethylene oxide) diols and poly(propylene oxide) diols or productsof reactions of different glycols. Linear polyester soft segment bockscommonly used include the polycondensation product of adipic acid andshort carbon-chain glycols. Polycaprolactones may also be used.Thermoplastic polyurethanes are commercially available from supplierssuch as DuPont®, Bayer®, Dow®, Noveon®, and BASP®.

The particular elastomeric material selected for use in an ECM fiber maydepend on a variety of factors including its spinning ability,bondability, the degree of resiliency required of the bonded fiberstructure formed from the fiber, and other characteristics related tothe use of the bonded fiber structure. A particular elastomeric materialmay be selected, for example, based on its relative hydrophobicity orhydrophilicity, or based on its compatibility with fluids or othermaterials expected to interact with the bonded fiber structure.

With any of the above-described ECM fiber embodiments 300, 400, 500,600, 700, care must be taken to assure that fiber integrity ismaintained throughout the manufacturing process. ECM fibers of theinvention may be produced using any of several methods, as detailed inco-pending U.S. patent application Ser. No. ______, filed on Mar. 14,2006 under Attorney Docket Number 61633.001139. Regardless of the methodof manufacture, however, specific processing parameters must be tailoredto the particular materials used in order to assure that viable fibersare produced. In sheath-core ECM fibers, for example, processingparameters must be tailored to assure complete coverage of the core andto assure that the sheath will remain adhered to the core.

Variations and modifications can be made to the ECM fibers and bondedfiber reservoirs without departing from the scope of the invention. Forexample, as described in U.S. Pat. No. 6,814,911, fibers, fiber webs andproducts formed therefrom may require or may be enhanced by, theincorporation of an additive in the fibrous web during manufacture.Accordingly, surfactants or other chemical agents in particularconcentrations may be added to the ECM fibers and/or ECM fiber webs tobe used in the formation of ink reservoirs for ink jet printercartridges. These additives may modify the surface characteristics ofthe ECM fibers to enhance absorptiveness and/or compatibility withparticular ink formulations. Similarly, particulate matter may beadhered to the ECM fibers or ECM fibrous webs in order to producecertain characteristics (e.g., increase absorptiveness).

Additionally, bimodal webs comprising ECM fibers may be formed. Methodsof forming such bimodal webs are described in U.S. Pat. No. 6,103,181.Bimodal webs are webs formed from a combination of fibers of differenttypes, materials and/or configurations. For example, a first fiber typemay be a sheath-core bicomponent ECM fiber in which the sheath materialis an elastomer and the core is a non-elastomer, and a second fiber typemay be an elastomeric or non-elastomeric monocomponent fiber. In someembodiments, a web may comprise a first sheath-core bicomponent ECMfiber in which the core material is an elastomer and the sheath may be anon-elastomer, and a second fiber type that may be a monocomponent fiberformed from the same elastomer as the core of the sheath-corebicomponent ECM fiber. In some embodiments, the fibrous web may beformed from alternating ECM fibers and multicomponent fibers with noelastomeric component. The bimodal fiber collection from any of thesevariations can be used to form a bonded web in which fibers of one typeserve to bond to each other and to fibers of the other type.

It is contemplated that the ECM fibers used to form bonded ECM fiberstructures may be in the form of bundled individual filaments,continuous filaments, filament tows, rovings of staple fibers, orlightly bonded or mechanically entangled webs or sheets of non-wovenstaple fibers. The ECM fibers may be mechanically crimped or may bestructured so that self-crimping may be induced (e.g., by stretching andthen relaxing the fibers) during the continuous forming process.Additionally, in some embodiments, substantially self-sustaining websformed from ECM fibers may be post-drawn to create more elastic crimpsalong the machine direction. The additional crimps may help to generatea loftier, bulkier and more elastic substrate.

Testing Procedures

The ink leakage and ink extraction properties of some embodiments of inkreservoirs in accordance with the invention were determined by thefollowing testing procedures:

Leak Testing Procedure

-   1. Bonded ECM fiber reservoirs were placed in ink jet printer    cartridges, and the reservoirs were loaded with 13.5 g of ink.    Thirty (30) minutes were allowed for the ink to equilibrate in the    cartridges.-   2. After the ink equilibrated in the cartridges, the cartridges were    then dropped onto a hard surface from a height of approximately 1    meter on each face of the cartridge, for a total of six drops per    cartridge. The cartridges were then checked for leakage. Any loss of    ink from the reservoir and cartridge qualified as a failure.-   3. If the cartridges passed the leakage drop test, the cartridges    were then subjected to vacuum leak testing. The cartridges were    placed in a vacuum chamber with the cartridge tops facing downward    and tested for leakage in the following manner:    -   a. The vacuum in the vacuum chamber was increased from 0.0 to        9.5 in Hg over 1 minute. This vacuum pressure was held for 2        minutes.    -   b. The vacuum in vacuum chamber was then increased from 9.5 to        12.5 in Hg over 1 minute. This pressure was held for 2 minutes.-   4. The vacuum was released and the cartridges were then removed from    the vacuum chamber and checked for any evidence of leakage. Any    visible loss of ink from the cartridge qualified as a failure.    Ink Extraction Testing Procedure-   1. Bonded ECM fiber reservoirs were placed in ink jet printer    cartridges, and the reservoirs were loaded with 13.5 g of ink.    Thirty (30) minutes were allowed for the ink to equilibrate in the    cartridges.-   2. After the ink equilibrated in the cartridges, the initial mass of    the cartridge was recorded.-   3. The cartridges were then placed in an ink extraction instrument,    and ink was extracted as follows:    -   a. Ink was extracted at a rate of 2 mL/minute until a total of 4        mL was extracted.    -   b. Ink was then extracted at a rate of 1 mL/minute until a        cumulative total of 5 mL was extracted.    -   c. Ink was then extracted at a rate of 0.5 mL/minute until a        cumulative total of 5.5 mL was extracted.    -   d. Ink was then extracted at a rate of 0.25 mL/minute until 8        in. H₂O of backpressure was reached.-   4. After the ink was extracted from the cartridge, the final mass of    the cartridge was recorded. Using the difference between the final    mass and the initial mass, the extraction efficiency of the    cartridge and reservoir were determined.

EXAMPLES

1) Ink Jet Printer Reservoirs Made From Melt-Blown ThermoplasticPolyurethane (TPU)/Polypropylene (PP) Sheath-Core Fibers

Melt-blown sheath-core bicomponent ECM fibers were formed using athermoplastic polyurethane (TPU)(Noveon® Estane® 74280) as a sheathmaterial and a polypropylene (PP) (Atofina® PP3860X, 100 melt flow rate(“MFR”)) as a core material. The TPU was initially dried for 4 hours at60° C. The sheath and core resins were melt-blown at temperaturesranging from 180°-245° C., with the die tip at 168° C. The ratio of TPUsheath material to PP core material was approximately 30:70 by volume.The resulting web displayed good bulk and softness. The produced web waspassed through a steam forming die and a chilled forming die to formrectangular rods which were then cut to the desired length. Theresultant bonded fiber structures were then inserted into ink jetprinter cartridges, filled with ink, and tested for ink extraction andresistance to leaking. The testing procedures are discussed above. Amatrix evaluating fiber size and reservoir densities was generated.(Table 1). A review of the results in Table 1 shows some embodiments ofTPU-based ink reservoirs in accordance with the invention provide inkextraction performance well over 70%.

2) Ink Jet Printer Reservoirs Made From Melt-Blown ElastomericPolypropylene (EPP)/Polypropvlene (PP) Sheath-Core Fibers

Melt-blown sheath-core bicomponent ECM fibers were formed using anelastomeric polypropylene (EPP) material (ExxonMobil® Vistamaxx® 2330)as the sheath material, and a PP material (Atofina® PP3860X) as the corematerial. The ratio of the sheath to core was approximately 30:70 byvolume. The sheath and core resins were melt blown at temperatures in arange from 200-290° C., with the die tip at 277° C. Fiber sizes ofapproximately 9 micron were obtained. The resulting web displayed goodbulk and softness. The produced web was then passed through a steamforming die to form rectangular rods which were then cut to the desiredlength. The resultant bonded fiber structures were then inserted intoink jet printer cartridges, filled with ink, and tested for inkextraction and resistance to leaking. The testing procedures arediscussed above. TABLE 1 Material (sheath- Reservoir Extraction (%)Initial Back core) Fiber Size Density Cyan ink, (γ) Pressure Leaks(30/70) (micron) (g/cc) 30 dyne/cm (in water) (yes/no) PET/PP 14.6 0.13563.6 2.3 No EPP/PP 9.0 0.131 54.0 5.8 No EPP/PP 9.0 0.101 57.6 4.9 NoTPU/PP 14.6 0.160 75.3% 1.3 No TPU/PP 14.6 0.127 74.1% 0.9 No TPU/PP13.4 0.132 69.6% 1.9 No TPU/PP 13.4 0.145 66.1% 2 No TPU/PP 13.4 0.18362.3% 2.5 No TPU/PP 10.5 0.132 69.9% 2.3 No TPU/PP 10.5 0.160 65.5% 2.7No TPU/PP 10.5 0.186 58.9% 3.5 No TPU/PP 26.7 0.105 77.1% 0.1 Yes TPU/PP26.7 0.132 76.7% 0.3 Yes TPU/PP 26.7 0.161 72.1% 0.9 Yes TPU/PP 26.70.183 67.6% 0.8 Yes TPU/PP 18.0 0.136 73.8% 1 Yes TPU/PP 18.0 0.16171.3% 1.2 Yes TPU/PP 18.0 0.186 67.3% 1.6 No

Table 2 provides relative ink absorption data, illustrating the amountof time required for inks of certain surface tension (γ) to be absorbedinto the ECM fiber matrix. Values for inks at a series of surfacetensions are provided for absorption into non-ECM fiber matrices(polyester sheathed sheath-core bicomponent fibers), sheath-corebicomponent ECM fibers with a hydrophobic TPU sheath material, andsheath-core bicomponent ECM fibers with a hydrophilic TPU sheathmaterial. TABLE 2 INK ABSORPTION DATA Ink Drop* (sec.) HP 14 FormulabsFormulabs Reservoir Characteristics Cyan Lexmark Lexmark Canon CanonFiber Reservoir Surface 12A1970 12A1912 BCI-21 BCI-21 Size Densitytension (γ) HP 14 Black Black Magenta Cyan Black Fiber Type (mm) (g/cc)30 dyne/cm γ 35 dyne/cm γ >42 dyne/cm γ 37 dyne/cm γ 35 dyne/cm γ 42.5dyne/cm TPU Estane 11 0.168 1 1 35 1 1 2.5 58245/PP Hydrophilic TPUEstane 15 0.155 1 >120 >120 40 1 >120 74280/PP Hydrophobic PET/PP 150.14 1 1 5 1 1 1*“Ink drop” is the rate of absorption of a drop of ink into the cut endof the fiber matrix. A smaller number means faster absorption.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the method, manufacture,configuration, and/or use of the present invention without departingfrom the scope or spirit of the invention.

1. An ink reservoir, comprising a three dimensional bonded fiberstructure, wherein the three dimensional bonded fiber structure iscomprised of a plurality of fibers bonded to each other at spaced apartpoints of contact, at least a portion of the fibers being multicomponentfibers having at least one elastomeric fiber component.
 2. The inkreservoir of claim 1, wherein the at least one elastomeric fibercomponent comprises a thermoplastic polyurethane.
 3. The ink reservoirof claim 1, wherein the at least one elastomeric fiber componentcomprises a material selected from the group consisting of elastomericand plastomeric polypropylenes, styrene-butadiene copolymers,polyisoprene, polyisobutylene, polychloroprene, butadiene-acrylonitrile,elastomeric block olefinic copolymers, elastomeric block co-polyetherpolyamides, elastomeric block copolyesters, poly(ether-urethane-urea),poly(ester-urethane-urea), and elastomeric silicones.
 4. The inkreservoir of claim 1, wherein the multicomponent fibers aremulticomponent fibers comprising: a thermoplastic polymer core material;and an elastomeric polymer sheath material surrounding the corematerial.
 5. The ink reservoir of claim 4, wherein the elastomericpolymer sheath material comprises a thermoplastic polyurethane.
 6. Theink reservoir of claim 4, wherein the thermoplastic core materialcomprises a second elastomeric material different from the elastomericpolymer sheath material.
 7. The ink reservoir of claim 4, wherein thethermoplastic core material is selected from the group consisting ofpolyethylene, polypropylene, nylon, polyester, polybutyleneterephthalate, and polyethylene terephthalate.
 8. The ink reservoir ofclaim 1, wherein the multicomponent fibers are melt-blown side-by-sidebicomponent fibers.
 9. The ink reservoir of claim 1, wherein the threedimensional bonded fiber structure has at least one dimension alongwhich the structure can be elongating at least 200% while retaining itsstructural integrity.
 10. The ink reservoir of claim 1, wherein thefibers have a diameter in a range from about 1 micron to about 200microns.
 11. The ink reservoir of claim 1, wherein the fibers have adiameter in a range from about 1 micron to about 25 microns.
 12. The inkreservoir of claim 1, wherein the fibers comprise materials that areselected, at least in part, for their compatibility with a particularink formulation.
 13. The ink reservoir of claim 1, wherein the bondedfiber structure is adapted to take up, hold, and controllably release aparticular ink formulation.
 14. An ink jet printer cartridge,comprising: a housing, defining a reservoir cavity; and a reservoir,disposed within the reservoir cavity, the reservoir comprising a threedimensional bonded fiber structure, wherein the three dimensional bondedfiber structure is comprised of a plurality of fibers bonded to eachother at spaced apart points of contact, at least a portion of thefibers being multicomponent fibers having at least one elastomeric fibercomponent.
 15. The ink jet printer cartridge of claim 14, wherein the atleast one elastomeric fiber component comprises a thermoplasticpolyurethane.
 16. The ink jet printer cartridge of claim 14, wherein theat least one elastomeric fiber component comprises a material selectedfrom the group consisting of elastomeric and plastomeric polypropylenes,styrene-butadiene copolymers, polyisoprene, polyisobutylene,polychloroprene, butadiene-acrylonitrile, elastomeric block olefiniccopolymers, elastomeric block co-polyether polyamides, elastomeric blockcopolyesters, poly(ether-urethane-urea), poly(ester-urethane-urea), andelastomeric silicones.
 17. The ink jet printer cartridge of claim 14,wherein the multicomponent fibers are multicomponent fibers comprising:a thermoplastic polymer core material; and an elastomeric polymer sheathmaterial surrounding the core material.
 18. The ink jet printercartridge of claim 17, wherein the elastomeric polymer sheath materialcomprises a thermoplastic polyurethane.
 19. The ink jet printercartridge of claim 17, wherein the thermoplastic core material comprisesa second elastomeric material different from the elastomeric polymersheath material.
 20. The ink jet printer cartridge of claim 17, whereinthe thermoplastic core material is selected from the group consisting ofpolyethylene, polypropylene, nylon, polyester, polybutyleneterephthalate, and polyethylene terephthalate.
 21. The ink jet printercartridge of claim 14, wherein the multicomponent fibers are melt-blownside-by-side bicomponent fibers.
 22. The ink jet printer cartridge ofclaim 14, wherein the three dimensional bonded fiber structure has atleast one dimension along which the structure can be elongating at least200% while retaining its structural integrity.
 23. The ink jet printercartridge of claim 14, wherein the fibers have a diameter in a rangefrom about 1 micron to about 200 microns.
 24. The ink jet printercartridge of claim 14, wherein the fibers have a diameter in a rangefrom about 1 micron to about 25 microns.
 25. The ink jet printercartridge of claim 14, wherein the fibers comprise materials that areselected, at least in part, for their compatibility with a particularink formulation.
 26. The ink jet printer cartridge of claim 14, whereinthe bonded fiber structure is adapted to take up, hold, and controllablyrelease a particular ink formulation.
 27. An ink jet printer,comprising: a carriage; a print-head mounted on the carriage; and an inkjet printer cartridge associated with the print-head, such that the inkjet printer cartridge provides the print-head with ink, and wherein theink jet printer cartridge comprises an ink reservoir formed from aplurality of fibers bonded to each other at spaced apart points ofcontact, at least a portion of the fibers being multicomponent fibershaving at least one elastomeric fiber component.
 28. The ink jet printerof claim 27, wherein the multicomponent fibers are multicomponent fiberscomprising: a thermoplastic polymer core material; and an elastomericpolymer sheath material surrounding the core material.